Upholstery assembly



Feb. 23, 1965 D. F. CALDEMEYER ETAL 3,170,731

UPHOLSTERY ASSEMBLY Filed Aug. l0, 1961 2 Sheets-Sheet l F I g. E

@AN/EL F. (vuoi/versn aora o. Caxafnfrfk By!! :wma M @anmewdas/l 5%; /0 Homey A 1N VEN TORS Feb. 23, 1965 D. F. cALDl-:Ml-:YER ETAI. 3,170,731

UPHOLSTERY ASSEMBLY 2 Sheets-Sheet 2 Filed Aug. 1o, 1961 INVENTORS DAN/EL Cfuozffnm L ara 0. Gual/verf# BY /l am: M. 00mm/ausl! @g/Af( for/zeg i .3,170,731 "urnorsrnnr ASSEMBLY Daniel F. Calderneyer, Lloyd L Caldemeyer, and Howard M. Quakenbush, Evansville, Ind., assignors to National Furniture Manufacturing Co., Inc., Evansville, Ind., a corporation of Indiana Filed Aug. 10, 1961, Ser. No. 130,603 8 Claims. (Cl. 297-452) The present inventionrelates to upholstered furniture,

' and more particularly to a new and novel upholstery assembly which pre-combines cushioning materialinto a unitary structure so as to facilitate the upholstering operation and at Vthe same time affordV a highly desirable finished furniture unit. j

As is known, heretofore it has been difficult to always satisfactorily preassemble components forming the seat` portion for upholstered furniture and, thereafter, to readily assemble the same onto the frame of the unit being upholstered. The preceding was particularly true in 4view of the increased usage of foam type cushioning, such as the commonly known polyurethane foam.

By virtue of therinstant invention, the applicants have provided a new and novel upholstery assembly for furniture whereby the upholstery may be conveniently preassembled and, thereafter, readily combined with the framework of the furniture during the upholstery operation. Briefly, the invention typically comprises cushioning members, mostly in the form of synthetic foams,V in pre-selected layers, Where one of the layers Vdefines an edge roll, and where all of the layers combine into an integral unit which is readily preassembled prior to ultimate manufacturing.

Accordingly, the principal object of the present invention is to provide a new and novel upholstery assembly for furniture.

Another object of the present invention is to provide a new and novel upholstery assembly for furniture which is readily preassembled for subsequent effective manufacturing procedures.

A still `further and more general object of the present invention is to provide an upholstery assembly for furniture which combines a minimum of components and which, at the same time, defines an edge roll on the aforesaid unit.

Other objects and a better understanding of the invention will become more apparent from the following description, taken in conjunction with the accompanying drawing, whereini f v FIG. l is a plan view showing the upholstery assembly forming the` instant invention; i fFIG. 2 is an exploded view in side elevation, showing the various components forming the upholstery assernblyV of FIG. 1;

FIG. 3 is another plan view of the instant invention, showing, however, its relationship with the lframework of an upholstered furniture unit;

FIG. 4 is a detailed view in vertical section, generally taken at line 4`4 of FIG. 3 and looking in the direction of the arrows, of the applicants new and novel upholstery assembly;

FIG. 5 is a view in vertical section of a modification of the instant invention;

FIG. 6 is a view in vertical section of another'modification of the instant invention;

FIG. 7 is a View in vertical section of still another modification of the instant invention; and

FIG. 8 is a view in vertical section of a further modilication of the instant invention.

For the purposes of promoting an understanding of the principles of the invention, reference will now be cer made to the embodiment illustrated inthe drawing and specific language will be used toV describe the same. It

will nevertheless be understood that no limitation ofthe scope of the invention is thereby intended, suchalterations and further modificationsV in the illustrated device, and such Yfurther applications of the principles of the invention as illustrated therein being ycontemplated as would normally occur to one skilled in the art to which the invention relates. Y

novel upholstery assembly 10 broadly comprises a layer of cushioning material 11, typically in the form of polyurethane foam, for example, having a scrim -12 secured by adhesive means 14 to a portion of the `bottom surface thereof. Disposed above the layer of cushioning material 11 is a preassembled relationship of other components which, in the preferred embodiment of the invention, comprises a relatively thin layer of cushioning material 16, typically in the form of polyurethane foam, for example, having a tapered or similar shaped portion 17 of cushioning material, also typically in the form of polyurethane foam, secured thereto by adhesive means 1S, the tapered portion 17 forming part of an edge roll for the finished upholstered unit, to be described herebelow. 1 l

Disposed beneath the layer of cushioning material 16, and secured thereto by adhesive means 21, is a layer of scrim 19. Denim or like material 22 isV disposed on the top surface of the cushioning material 16, where the aforesaid denim 22 has a cover fabric 23 disposed along one edge thereof. As will be apparent from the following discussion, the cover fabric 23, the denim 22, and the layer of cushioning material licombined with the scrim 19 are preassembled at a stitching line 25, where the latter, when in position on an upholstered unit, is not visible, inasmuch as the cover fabric 23 is pulled forwardly thereover (see FIG. 4).

With particular reference now to FIG. 3, the applicants new and novel upholstery assembly 10 is typically disposed on a framework for an upholstered furniture unit defined by a front rail 30, side rails 31, and a rear rail 32, whose legs 34 are provided to support the aforesaid framework. The furniture unit further includes ai combination arm-'back 3S, and in a typical embodiment f assembled through operational steps comprising, for example, the securing together Iof tapered portion 17 on the relatively thin layer of cushioning'material 16, through adhesive means 18. It should be noted that the scrim 19 may already be preassembled to the layer of cushioning material 16 through adhesive means 21, or such assembly may take place at this step of the operational procedures.

Thereafter, the cover fabric 23 is disposed on the denim or likematerial 22 so that the ultimate outward surfaces thereof are in face-to-face relationship. Edges of the aforesaid cover fabric 23 and the denim or like material 22 are then sewed together with the layer of cushioning material 16 having the scrim 19 secured thereto at a stitchingrline 25 disposed immediately adjacent the rear edge of the tapered portion 17. It might be noted that the stitching line 25 is shown in a somewhat exaggerated position behind the aforesaid tapered portion 17 in the figures for reasons of clarity.

Thereafter, the adhesive means 20 is spread onto and over the top surface of the cushioning material 11 and Referring now to the figures, theapplicants new andA l the aforedescribed subassembly is placed thereon so that the scrim 19 is in contact therewith. The applicants invention, therefore, now affords an integral preassembled unit which is ready for subsequent manufacturing procedures. i

In this latter connection, the upholstery assembly 1t! is then disposed on the supporting structure 35 which extends between the front rail 30, the side rails 31 and the rear rail 32 of the unit being upholstered. The scrim 12 is then secured to the front surface of the front rail 30, followed by the scrim 19, which is also secured thereto, with the opposite end of the latter being drawn towards and secured (not shown in the drawing) to the rear rail 32. Similarly, the rear edge of the denim or like material 22 is secured to the rear rail 32 of the upholstered unit, while the cover fabric 23 is drawn forwardly over the tapered portion 17, downwardly along the front of the upholstered unit, and typically secured to the undersurface of the front rail 30. In this latter connection, it should be noted that the tapered portion 17 provides an edge roll for the finished unit where the stitching line 25 thereof is not visible, in that the fabric cover 23 is drawn forwardly over the stitching line 25, thereby affording a highly desirable neat appearing finished surface.

With reference now to FIG. 5, a modification of the instant invention is disclosed defined by the aforesaid cushioning material 11 having the layer of cushioning material 16 disposed thereover, with scrim 19 being positioned between the cushioning materials 11 and 16 by the use of an adhesive 38. In this instance, however, the assembly includes the use of a slab of paperboard, or hardboard or like material 40, typically disposed on cushioning material 16 by adhesive means 41, where in the preferred form of this modification of the invention, the cover fabric 23 and the denim 22 are secured thereto at a stitching line 42. As in the arrangement of FIGS. 1 to 4, inclusive, a tapered portion 17 of cushioning material is employed, where the latter is disposed on the slab 40 and retained in position by adhesive means 44. As should be apparent from the drawing, the cover fabric 23 is drawn forwardly and downwardly over the tapered portion 1'7.

FIG. 6 discloses another embodiment of the invention, wherein, however, the cushioning material 16 and the scrim 19 are disposed on a spring 5f) which extends between the front rail 30 of the unit and the rear rail (not shown). The forward portion of the cushioning material 16 is secured to the scrim 19 by adhesive means 51 and is laid over a slab 40, where the latter is typically retained in position on the spring t) by the same screw means which secure the scrim 19 to the front rail 30'. As in the form of invention of the preceding figures, a tapered portion 17 of cushioning material is retained on the cushioning material 16 by adhesive means 44, and the slab 40, the scrim 19, the cushioning material 16, the denim 22 and .the cover fabric 23 are secured together at a stitching line 42, with the cover fabric 23 :being drawn over the tapered portion 17 of cushioning material.

With reference now to FIG. 7, an alternate form of the invention is disclosed wherein the slab 40 is disposed between the front portions of the cushioning materials 11 and 15, and where such assembled relationship is retained by adhesive means 55. Again, as discussed hereabove, a stitching line 42 joins the slab 40, the cushioning material 16, the denim 22 and the cover fabric 23, where the latter is drawn over a tapered portion 17 which is secured to the cushioning material 16 by adhesive means 44.

The alternate embodiment of the invention of FIG. 8 discloses a conical spring 60" having the slab 41B disposed on the top thereof and wrapped around its leading edge. A stitching line 61 joins scrim 19 and the folded portion of the slab 40. A stitching line 42 joins the slab 4t), a cushioning material 16 disposed thereover, and the aforedescribed denim Z2 and the cover fabric 23.

It should be understood that the use of the slab 40 in the various modifications `of the invention of FIGS. 5 to 8, inclusive, serves to keep the edge of the upholstered unit neat, as well as prevents same from becoming concave or convex when in use, thus representing an important contribution to the furniture art.

From the preceding, it should be apparent that the applicants have invented a new and novel upholstery assembly which is readily preassembled in several subassemblies, and which is thereafter conveniently installed in the desired upholstered unit through relatively simple manufacturing operations.

It should be Vunderstood that the upholstery assembly described hereabove is susceptible to various changes within the spirit of the invention. For example, although a T-type cushion is disclosed by the drawing, it is obvious that other cushioning can be effectively assembled through the instant invention. Further, the precise assembly operation described hereabove can be varied with equally satisfactory end results. In this latter regard, it should be understood that the units may be subassembled in other combinations of components. In addition, certain of the components may be eliminated, as, for example, the scrim 12, without serious effect to the use of the invention. Additionally, the tapered portion 17 can be combined with the cushioning member 16 as an integral unit, and the slab 40 disposed thereunder, for equally effective results. Thus, the above description should be considered illustrative and not as limiting the scope of the following claims.

We claim:

l. A preassembled upholstery assembly for the seat portion of upholstered furniture comprising a first cushioning layer, a second cushioning layer disposed over said first cushioning layer, a third cushioning layer disposed on a portion of said second cushioning layer, a base fabric disposed on another portion of said second cushioning layer, and a cover fabric secured to said base fabric at a stitching line combining said cover fabric, said base fabric and said second cushioning layer, said cover fabric extending over said third cushioning layer and concealing said stitching line.

2. A preassembled upholstery assembly for the seat portion of upholstered furniture comprising a first cushioning layer, a second cushioning layer disposed over said first cushioning layer, a first fabric disposed between said first cushioning layer and said second cushioning layer, a third cushioning layer disposed on a portion of said second cushioning layer, a base fabric disposed on another portion of said second cushioning layer, and a cover fabric secured to said base fabric at a stitching line combining said cover fabric, said base fabric, said second cushioning layer and said first fabric, said cover fabric extending over said third cushioning layer and concealing said stitching line.

3. The preassembled upholstery assembly of claim 2 where another fabric is secured to the bottom portion of said first cushioning layer.

4. An upholstery assembly for thenseat portion of upholstered furniture comprising, in combination, a first preasembled sub-assembly defined by a first cushioning layer, a first fabric secured to the bottom surface of said first cushioning layer, a second cushioning layer secured to a portion of said first cushioning layer, a base fabric disposed on another portion of said first cushioning layer, and a cover fabric secured to a portion of said base fabric at a stitching line extending through said cover fabric, said base fabric, said first cushioning layer and said first fabric, and a second preassembled subassembly defined by a third cushioning layer and another fabric secured to a portion of the bottom surface thereof, where said first subassembly and said second preassembled subassembly are secured together to define a unitary structure.

5. The preassembled upholstery assembly of claim 4 where said cover fabric extends over said second cushioning layer to conceal said stitching line.

3,1 royrs 1 6. In combination with upholstered furniture defined by a framework, an upholstery assembly comprising a first cushioning layer, a second cushioning layer disposed over said rst cushioning layer, a rst fabric disposed between said first cushioning layer and said second cushioning layer, a third cushioning layer disposed on a portion of said second cushioning layer, a base fabric disposed on another portion of said second cushioning layer, a cover fabric secured to said base fabric at a stitching line combining said cover fabric, said base fabric, said second cushioning layer and said first fabric, said cover fabric extending over said third cushioning solely supported by said first and second cushioning layers 'and spaced from said framework.

layer and concealing said stitching line, and another v fabric secured to the bottom portion of said rst cushioning layer, said first fabric and said another fabric having portions secured to said framework of said upholstered furniture.

7. An upholstery assembly comprising, in combination, a framework, a first cushioning layer supported by said framework, a second cushioning layer, and a relatively stif, non-resilient material suspended between said rst and said second cushioning layers, said material 8. An upholstery assembly comprising, in combination,a rst cushioning layer supported by said frame- Work, a second cushioning layer disposed on said first cushioning layer, a third cushioning layervdisposed on said second cushioning layer, and a relatively stiff, nonresilient material suspended between said third and said second cushioning layers in spaced relationship to said framework and solely supported by said first and second cushioning layers.

References Cited by the Examiner UNITED STATES PATENTS FRANK B. SHERRY, Primary Examiner. E GEORGE L. BREHM, Examiner. 

1. A PREASSEMBLED UPHOLSTERY ASSEMBLY FOR THE SEAT PORTION OF UPHOLSTERED FURNITURE COMPRISING A FIRST CUSHIONING LAYER, A SECOND CUSHIONING LAYER DISPOSED OVER SAID FIRST CUSHIONING LAYER, A THIRD CUSHIONING LAYER DISPOSED ON A PORTION OF SAID SECOND CUSHIONING LAYER, A BASE FABRIC DISPOSED ON ANOTHER PORTION OF SAID SECOND CUSHIONING LAYER, AND A COVER FABRIC SECURED TO SAID BASE FABRIC AT A STITCHING LINE COMBINING SAID COVER FABRIC, SAID BASE FABRIC AND SAID SECOND CUSHIONING LAYER, SAID COVER FABRIC EXTENDING OVER SAID THIRD CUSHIONING LAYER AND CONCEALING SAID STITCHING LINE. 